Abstract: Based on virtual reality technology, a friendly human-computer interaction interface and virtual machining environment were developed by Visual C++ and OpenGL. Considering the inhomogeneity of grain size and randomicity of grain distribution, virtual grinding wheel was modeled by taking ortho-hexahedron as basic shape of abrasive grains and randomly distributes them on the wheel base. Mathematic model of interference between abrasive grain and workpiece was established. By using the virtual grinding wheel modeled, surface grinding processes with different machining parameters were simulated. The simulation results show that the system could make operators have a further understanding to chip formation, and the machining results could reflect realistic surface topography of workpiece. Complex grinding process can be realistically simulated. It provides visualization models for the research of grinding mechanism and production forecast.

Abstract: Abrasive machining is an important process for the manufacturing of advanced ceramics. The demand for advanced ceramics with better quality and higher efficiency presents tremendous challenges for abrasive tools in the advanced ceramics industry. The concept of semi-fixed abrasive machining with a newly developed semi-fixed abrasive tool (SFAT) as machining tool is put forward. This paper presents an experimental investigation for SFAT wear into course of machining single crystal silicon with SFAT. Process parameters (water flow, load and velocity) influencing the SFAT wear are analyzed. Influencing factor of SFAT wear in processing course has been clearly demonstrated.

Abstract: A lapping and polishing technology of flotation cushion was studied and some improved equipments were carried out to polish flotation cushion with the structure of variable-section pressure equalizing groove. Main parameters of lapping and polishing (e.g. abrasive disk rotate speed, abrasive disk stress, abrasive category, abrasive grain diameter, slurry density and abrasive disk material) were changed to find out impact parameters of surface quality. Optimization parameters of lapping and polishing of cushion were gotten and mirror finish was achieved. Experiments show that the processed surface with this technology is pinch rolling and no scratch based on the optimization parameters.

Abstract: A highly efficient precision grinding method was proposed for the development of Zr-4 alloy used in nuclear industry. The key techniques to develop this new grinding machine are presented in detail, including soft grinding wheel head, ultrasonic thickness measurement system. An automatic polishing and grinding system was built, which is based on ultrasonic thickness measurement technology. According to a lot of grinding experiments, reasonable, accurate and efficient Zr-4 Alloy grinding parameters was determined. The experiments show that when the line speed of belt is about 18 m/s; the workpiece feed rate is 1000mm/min; grinding head cylinder pressure is 0.12Mpa, the silicon carbide abrasive belt of P80 particle size can get 0.02mm grinding amount and achieve excellent grinding effect.

Abstract: The compressor blade is the key components of the aero-engine to seriously impact the air dynamic performance. However, components with complex designs specifications might pose manufacturing challenges especially when finishing processes are needed to enable their compliance with tight industrial standards for workpiece surface integrity. Information on polishing processes for such sensitive industrial applications is scarce. The paper reports on the influence of polishing methods on the surface integrity of compressor blade obtained after different polishing methods. The research focuses on identifying an “optimised” polishing method for different area that will enable finishing the compressor blade. Two (belt; bob) polishing methods have been tested to address the overall finishing of compressor blade. Although significant differences in tool life performance exist between belt and bob polishing methods, both are capable to meet the requirements of minimum workpiece surface coverage if “optimised” operating parameters are employed. This is proved that belt and bob polishing methods can be employed to enable automated overall finishing of compressor blade.